2009 YAMAHA WR 250R fuel cap

TABLE OF CONTENTS
SAFETY INFORMATION
...................1-1
DESCRIPTION
...................................2-1
Left view ...........................................2-1
Right view .........................................2-2
Controls and instruments..................2-3
INSTRUMENT AND CONTROL
FUNCTIONS
........................................3-1
Main switch/steering lock .................3-1
Indicator and warning lights .............3-2
Multi-function display .......................3-3
Handlebar switches .........................3-8
Clutch lever ......................................3-9
Shift pedal ......................................3-10
Brake lever ....................................3-10
Brake pedal ...................................3-10
Fuel tank cap .................................3-11
Fuel ................................................3-11
Catalytic converter .........................3-13
Seat ...............................................3-13
Helmet holder ................................3-14
Adjusting the front fork ...................3-14
Front fork bleeding .........................3-16
Adjusting the shock absorber
assembly ....................................3-17
EXUP system ................................3-18
Sidestand .......................................3-19
Ignition circuit cut-off system .........3-19
FOR YOUR SAFETY –
PRE-OPERATION CHECKS
.............. 4-1
OPERATION AND IMPORTANT
RIDING POINTS
.................................. 5-1
Starting the engine .......................... 5-1
Shifting ............................................ 5-2
Tips for reducing fuel
consumption ................................ 5-3
Engine break-in ............................... 5-3
Parking ............................................ 5-4
PERIODIC MAINTENANCE AND
ADJUSTMENT
.................................... 6-1
Owner’s tool kit ................................ 6-1
Periodic maintenance chart for the
emission control system .............. 6-2
General maintenance and
lubrication chart ........................... 6-3
Removing and installing panels ...... 6-7
Checking the spark plug .................. 6-9
Engine oil and oil filter element ..... 6-10
Coolant .......................................... 6-13
Cleaning the air filter element
and check hose .......................... 6-16
Adjusting the engine idling
speed ......................................... 6-18
Checking the throttle cable free
play ............................................ 6-18
Valve clearance ............................. 6-19
Tires .............................................. 6-19Spoke wheels ............................... 6-21
Adjusting the clutch lever free
play ............................................ 6-21
Adjusting the brake lever free
play ............................................ 6-22
Adjusting the rear brake light
switch ......................................... 6-23
Checking the front and rear brake
pads ........................................... 6-23
Checking the brake fluid level ....... 6-24
Changing the brake fluid ............... 6-25
Drive chain slack ........................... 6-25
Cleaning and lubricating the
drive chain ................................. 6-26
Checking and lubricating the
cables ........................................ 6-27
Checking and lubricating the
throttle grip and cable ................ 6-27
Checking and lubricating the
brake and clutch levers .............. 6-28
Checking and lubricating the
brake pedal ................................ 6-28
Checking and lubricating the
sidestand ................................... 6-29
Lubricating the rear suspension .... 6-29
Checking the front fork .................. 6-29
Checking the steering ................... 6-30
Checking the wheel bearings ........ 6-31
Battery ........................................... 6-31
Replacing the fuses ...................... 6-32
Replacing the headlight bulb ........ 6-33

DESCRIPTION
2-3
1
2
3
4
5
6
7
8
9

EAU10430
Controls and instruments
12 34 5 6
8
7

1. Clutch lever (page 3-9)
2. Left handlebar switches (page 3-8)
3. Main switch/steering lock (page 3-1)
4. Multi-function display (page 3-3)
5. Right handlebar switches (page 3-8)
6. Brake lever (page 3-10)
7. Throttle grip (page 6-18)
8. Fuel tank cap (page 3-11)

INSTRUMENT AND CONTROL FUNCTIONS
3-11
2
34
5
6
7
8
9

EAU44363
Fuel tank cap
To remove the fuel tank cap
1. Insert the key into the lock and turn
it counterclockwise as shown.
2. Turn the fuel tank cap counter-
clockwise and pull it off.
To install the fuel tank cap
1. Insert the fuel tank cap into the
tank opening with the key inserted
in the lock, and then turn the cap
clockwise.
2. Turn the key clockwise, and then
remove it.
TIP

The fuel tank cap cannot be installed
unless the key is in the lock. In addition,
the key cannot be removed if the cap is
not properly installed and locked.
WARNING

EWA10121
Make sure that the fuel tank cap is
properly closed and locked before
riding. Leaking fuel is a fire hazard.
EAU13212
Fuel
Make sure there is sufficient gasoline in
the tank.
WARNING

EWA10881
Gasoline and gasoline vapors are
extremely flammable. To avoid fires
and explosions and to reduce the
risk of injury when refueling, follow
these instructions.
1. Before refueling, turn off the en-
gine and be sure that no one is sit-
ting on the vehicle. Never refuel
while smoking, or while in the vi-
cinity of sparks, open flames, or
other sources of ignition such as
the pilot lights of water heaters and
clothes dryers.
2. Do not overfill the fuel tank. Stop
filling when the fuel reaches the
bottom of the filler tube. Because
fuel expands when it heats up,
heat from the engine or the sun
can cause fuel to spill out of the
fuel tank.
1. Key
2. Fuel tank cap
1
2

1. Key
2. Fuel tank cap1
2

INSTRUMENT AND CONTROL FUNCTIONS
3-12
1
2
3
4
5
6
7
8
9
3. Wipe up any spilled fuel immedi-
ately.
NOTICE:
Immediately wipe
off spilled fuel with a clean, dry,
soft cloth, since fuel may deteri-
orate painted surfaces or plastic
parts.

[ECA10071]

4. Be sure to securely close the fuel
tank cap.
WARNING

EWA15151
Gasoline is poisonous and can
cause injury or death. Handle gaso-
line with care. Never siphon gaso-
line by mouth. If you should swallow
some gasoline or inhale a lot of gas-
oline vapor, or get some gasoline inyour eyes, see your doctor immedi-
ately. If gasoline spills on your skin,
wash with soap and water. If gaso-
line spills on your clothing, change
your clothes.
EAU13390
NOTICE

ECA11400
Use only unleaded gasoline. The use
of leaded gasoline will cause severe
damage to internal engine parts,
such as the valves and piston rings,
as well as to the exhaust system.
Your Yamaha engine has been de-
signed to use premium unleaded gaso-
line with a research octane number of
95 or higher. If knocking (or pinging) oc-
curs, use a gasoline of a differentbrand. Use of unleaded fuel will extend
spark plug life and reduce maintenance
costs.
1. Fuel level
2. Fuel tank filler tube
2
1

Recommended fuel:
PREMIUM UNLEADED GASOLINE
ONLY
Fuel tank capacity:
7.6 L (2.01 US gal, 1.67 Imp.gal)
Fuel reserve amount (when the fuel
level warning light comes on):
2.1 L (0.55 US gal, 0.46 Imp.gal)

MOTORCYCLE CARE AND STORAGE
7-4
2
3
4
5
6
78
9
fuel from deteriorating.
3. Perform the following steps to pro-
tect the cylinder, piston rings, etc.
from corrosion.
a. Remove the spark plug cap
and spark plug.
b. Pour a teaspoonful of engine oil
into the spark plug bore.
c. Install the spark plug cap onto
the spark plug, and then place
the spark plug on the cylinder
head so that the electrodes are
grounded. (This will limit spark-
ing during the next step.)
d. Turn the engine over several
times with the starter. (This will
coat the cylinder wall with oil.)
e. Remove the spark plug cap
from the spark plug, and then
install the spark plug and the
spark plug cap.
WARNING! To
prevent damage or injury
from sparking, make sure to
ground the spark plug elec-
trodes while turning the en-
gine over.

[EWA10951]

4. Lubricate all control cables and the
pivoting points of all levers andpedals as well as of the sidestand/
centerstand.
5. Check and, if necessary, correct
the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground. Alterna-
tively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
6. Cover the muffler outlet with a
plastic bag to prevent moisture
from entering it.
7. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an ex-
cessively cold or warm place [less
than 0 °C (30 °F) or more than 30
°C (90 °F)]. For more information
on storing the battery, see page
6-31.
TIP

Make any necessary repairs before
storing the motorcycle.

8-1
1
2
3
4
5
6
7
8
9

SPECIFICATIONS
EAU2633T

Dimensions:
Overall length:
2180 mm (85.8 in)
Overall width:
810 mm (31.9 in)
Overall height:
1230 mm (48.4 in)
Seat height:
930 mm (36.6 in)
Wheelbase:
1420 mm (55.9 in)
Ground clearance:
300 mm (11.81 in)
Minimum turning radius:
2300 mm (90.6 in)
Weight:
With oil and fuel:
134.0 kg (295 lb)
Engine:
Engine type:
Liquid cooled 4-stroke, DOHC
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
250.0 cm
3

Bore
×
stroke:
77.0
×
53.6 mm (3.03
×
2.11 in)
Compression ratio:
11.80 :1
Starting system:
Electric starter
Lubrication system:
Wet sump

Engine oil:
Type:
SAE 10W-30, SAE 10W-40, SAE 10W-50,
SAE 15W-40, SAE 20W-40 or SAE
20W-50
Recommended engine oil grade:
API service SG type or higher, JASO stan-
dard MA
Engine oil quantity:
Without oil filter element replacement:
1.30 L (1.37 US qt, 1.14 Imp.qt)
With oil filter element replacement:
1.40 L (1.48 US qt, 1.23 Imp.qt)
Cooling system:
Coolant reservoir capacity (up to the maxi-
mum level mark):
0.25 L (0.26 US qt, 0.22 Imp.qt)
Radiator capacity (including all routes):
0.90 L (0.95 US qt, 0.79 Imp.qt)
Air filter:
Air filter element:
Wet element
Fuel:
Recommended fuel:
Premium unleaded gasoline only
Fuel tank capacity:
7.6 L (2.01 US gal, 1.67 Imp.gal)
Fuel reserve amount:
2.1 L (0.55 US gal, 0.46 Imp.gal)
Fuel injection:
Throttle body:
Type/quantity:
38EIS/1
Spark plug (s):
Manufacturer/model:
NGK/CR9EK
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
Clutch:
Clutch type:
Wet, multiple-disc
Transmission:
Primary reduction system:
Spur gear
Primary reduction ratio:
78/25 (3.120)
Secondary reduction system:
Chain drive
Secondary reduction ratio:
43/13 (3.308)
Transmission type:
Constant mesh 6-speed
Operation:
Left foot operation
-20 -10 0
10 20 30
40
50 ˚C
SAE 10W-30
SAE 15W-40SAE 20W-40SAE 20W-50
SAE 10W-40SAE 10W-50

SPECIFICATIONS
8-3
1
2
3
4
5
6
7
8
9Battery:

Model:
YTZ7S
Voltage, capacity:
12 V, 6.0 Ah
Headlight:
Bulb type:
Halogen bulb
Bulb voltage, wattage
×
quantity:
Headlight:
12 V, 60 W/55 W
Tail/brake light:
LED
Front turn signal light:
12 V, 10.0 W
×
2
Rear turn signal light:
12 V, 10.0 W
×
2
Auxiliary light:
12 V, 5.0 W
×
1
License plate light:
12 V, 5.0 W
Meter lighting:
EL (Electroluminescent)
Neutral indicator light:
LED
High beam indicator light:
LED
Turn signal indicator light:
LED
Fuel level warning light:
LED
Coolant temperature warning light:
LEDEngine trouble warning light:
LED

Fuses:
Main fuse:
30.0 A
Headlight fuse:
15.0 A
Signaling system fuse:
10.0 A
Ignition fuse:
7.5 A
Radiator fan fuse:
7.5 A
Fuel injection system fuse:
7.5 A
Backup fuse:
7.5 A

INDEX
A
Air filter element and check hose,
cleaning .................................................6-16
Auxiliary light bulb, replacing ...................6-36
B
Battery .....................................................6-31
Brake and clutch levers, checking and
lubricating ..............................................6-28
Brake fluid, changing ...............................6-25
Brake fluid level, checking .......................6-24
Brake lever ..............................................3-10
Brake lever free play, adjusting ...............6-22
Brake pedal .............................................3-10
Brake pedal, checking and lubricating .....6-28
C
Cables, checking and lubricating .............6-27
Care ...........................................................7-1
Catalytic converter ...................................3-13
Clutch lever ................................................3-9
Clutch lever free play, adjusting ..............6-21
Coolant ....................................................6-13
Coolant temperature warning light .............3-2
D
Dimmer switch ...........................................3-9
Drive chain, cleaning and lubricating .......6-26
Drive chain slack .....................................6-25
E
Engine break-in .........................................5-3
Engine idling speed .................................6-18
Engine oil and oil filter element ................6-10
Engine stop switch.....................................3-9
Engine trouble warning light ......................3-3
EXUP system ..........................................3-18
F
Front and rear brake pads, checking....... 6-23
Front fork, adjusting................................. 3-14
Front fork, bleeding ................................. 3-16
Front fork, checking ................................. 6-29
Fuel ......................................................... 3-11
Fuel consumption, tips for reducing .......... 5-3
Fuel level warning light .............................. 3-2
Fuel tank cap ........................................... 3-11
Fuses, replacing ...................................... 6-32
H
Handlebar switches ................................... 3-8
Headlight bulb, replacing ......................... 6-33
Helmet holder .......................................... 3-14
High beam indicator light ........................... 3-2
Horn switch................................................ 3-9
I
Identification numbers ............................... 9-1
Ignition circuit cut-off system ................... 3-19
Indicator and warning lights....................... 3-2
K
Key identification number .......................... 9-1
L
License plate light bulb, replacing ........... 6-35
M
Main switch/steering lock .......................... 3-1
Maintenance and lubrication, periodic ....... 6-3
Maintenance, emission control system ..... 6-2
Matte color, caution ................................... 7-1
Model label ................................................ 9-2
Multi-function display ................................. 3-3
N
Neutral indicator light................................. 3-2
P
Panels, removing and installing ................ 6-7
Parking ...................................................... 5-4
Part locations ............................................ 2-1
R
Rear brake light switch, adjusting ........... 6-23
Rear suspension, lubricating ................... 6-29
S
Safety information ..................................... 1-1
Seat ......................................................... 3-13
Shifting ...................................................... 5-2
Shift pedal ............................................... 3-10
Shock absorber assembly, adjusting ...... 3-17
Sidestand ................................................ 3-19
Sidestand, checking and lubricating........ 6-29
Spark plug, checking ................................. 6-9
Specifications ............................................ 8-1
Starting the engine .................................... 5-1
Start switch................................................ 3-9
Steering, checking................................... 6-30
Storage...................................................... 7-3
Supporting the motorcycle ...................... 6-36
T
Tail/brake light ......................................... 6-34
Throttle cable free play, checking ........... 6-18
Throttle grip and cable, checking and
lubricating ............................................. 6-27
Tires ........................................................ 6-19
Tool kit....................................................... 6-1
Troubleshooting ...................................... 6-39
Troubleshooting charts............................ 6-41
Turn signal indicator light .......................... 3-2
Turn signal light bulb, replacing .............. 6-35
Turn signal switch ..................................... 3-9